1. Design File Preparation
Using SolidWorks
Ensure all parts of the crutch handle, frame, forearm support, and feet are designed and saved in the proper format (three-dimensional printing STL Computer Numerical Control/ machining DXF or STEP).
2. 3D Printing Prototypes
Materials Required:
3D printer: FDM or SLA
Filament-PLA, ABS, or PETG, for instance
Slicing software, with examples like Cura, PrusaSlicer
Steps:
Fabrication Models: Export each component again as an STL file from SolidWorks.
Load into Slicing Software: Load the STL files into your selected slicing software.
Configure Print Settings:
Set layer height-for example, 0.2 mm; this is a good balance of speed and detail.
Select the infill density - 20%, for instance, for light prototypes.
Activate support structures if necessary.
G-code Generation: Write the code to generate the .gcode file for your printer.
Prepare the Printer:
Load the filament into the printer.
Calibrate the printer bed if necessary.
Start Printing: Begin the print job and monitor the process for any issues.
Post-processing:
Remove supports carefully.
Sand or provide smooth surfaces for comfort where necessary.
3. CNC Machining Prototypes
Materials Needed:
CNC machine
Suitable material blocks (e.g., aluminum, wood, or plastic)
CAM software, like Fusion 360
Steps:
Export Models: Export your designed models in SolidWorks as DXF or STEP files.
Import into CAM Software: Import of design files to the CAM software.
Define Toolpaths:
At this step, choose the appropriate tool based on the material and requirements of the design: end mills, drills.
Define cutting speeds and feed rates.
Generate NC Code: Post-process to create NC code compatible with your CNC machine.
Setting up the CNC machine:
Securely fasten the block of material on the machine bed.
Load the spindle with the needed tools.
Program Run: The machining process now starts, observing for accuracy and safety.
Finishing Touches:
Debur the edges and clean the surfaces after machining to make them safe and comfortable.
4. Assembly of Prototype Components
Once the parts are fabricated, the following represents how to assemble them:
Gather Materials:
All parts fabricated
Fasteners-screws, bolts
Tools: screwdriver and wrench
Attach Handles to Frame:
Align handles with their designated slot on the frame.
Secure using screws or bolts.
Install Forearm Supports:
Place forearm supports at desired height on frame.
Fix them with adjustable clamps or screws.
Apply Shock-Absorbing Feet:
Securely insert feet into the bottom of each crutch leg.
Final Adjustments:
Test all adjustable components for smooth operation.
Safety Check:
Check all connections before use for defects and stability.